Method and apparatus for the manufacture of upholstery



Oct. l1, 1938. A A. s. MITCHELL 2,132,429

METHOD AND APPARATUS Fon THE MANUFACTURE oF UPHOLSTERY Filed Apg-f1 17,1955 s sheets-sheet 1 w1- k mil/f Oct. l1, 1938. A. s. MITCHELL METHODAND APPARATUS FOR THE MANUFACTURE OF `UPHOLSTERY Filed April 17, 1935 3Sheets-Sheet 2 Zr Z M M YZO/00%@ A. S. MITCHELL Oct. 11, 1938. 2,132,429

METHOD AND APPARATUS FOR THE MANUFAGTURE oP UPHOLSTERY Filed April 17,'19:55

3 Sheets-Sheet 3 Patented Oct. 11, 1938 UNITED STATES mz'rnon AND mmwrnsron 'rmt MAN- UrAc'rUnE -orUrnoLs'rEar Allister'S. Mitchell, Detroit,Mich.,` assigner to National Automotive Fibres, Inc., Detroit, Mich., acorporation ot Delaware Application April 17, 1935. Sorill N0. 16,868'

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This invention' relates particularly to upholstery adapted for use inautomobiles, etc., and to a method and machine for manufacturing thesame.

The primary object of the invention is to provide vupholstery ofimproved construction and appearance which may be used in making stuffedcushions or may be used to 'cover panels for the lining of an automobileor the like.

A further object of the invention is to provide a new type of seambetween pleats of a cushion which may be described as M-shaped.

In the use of the improved machine, as preferably constructed, pre-cutrcovers, a lining-fabric and strips of batting are fed through themachine, the pre-cut covers being iowermost; the lining-fabric hasformed therein upstanding seam-ridges; the pre-cut covers are fed,seriatim, overa suitable b ed and provided with upstanding seam-ridges4and intervening depressed pleats, the seam-ridges of the coversbecoming nested with the seam-ridges of the lining-fabric. Strips ofcotton batting or the like are drawn thrbugh with the fabrics and 1111the pleats; and the upstanding nested seam-ridges of the lining-fabricand of the pre-cut covers (suitably spaced) are sewed by means of sewingmechanisms mounted on a cross beam above the path of the materials, eachsewing mechanism preferably having a head carrying a sewing-needle and alouper-needle.

The covers are fed continuously through the machine and are connected inseries either by lining-fabric or tapes which. serve .as backings forthe seam-ridges. The cotton batts may be continuous strips and the coverfabrics are sewed to the lining. Ii desired, the batts fed to the pleatsare periodically broken. to correspond with the spaces between thecovers, so that the upholstery produced is a continuous piece composedof a series of `cushions connected by short lengths of lining-fabric ortapes. The lining-fabric may be cut at the spaces between the covers toeffect separation of the. cushions.

In the present machine, use is made of a suction-conveyor and associatedspaced ridges adapted to form seam-ridges and intervening (Cl. Ilz-2).

patent, No. 1,918,284, the .application for which was iiled October 30,1930.

The invention is illustrated in a preferred embodlment in theaccompanying drawings, in which- Figure 1 is a broken side elevationalview of ai machine embodying the` invention; Fig. 2, a broken sideelevational view of the improved ridge-bar; Fig. 3, a sectional viewtaken as indicated at line 3 of Fig. 1; Fig. 4, a. broken sectional viewtaken as indicated at line 4 of Fig. 1; Fig. 5, a broken sectional viewtaken as indicated at line 5 of Fig. 1; Fig. 6, a broken sectional viewtaken as indicated atllne 6 of Fig. l; Fig. '7, a broken sectional viewtaken as indicated at line 1 of Fig. 1; Fig. 8, a broken sectional viewtaken as indicated at 8--8 of Fig. 1; Fig. 9, a broken sectional viewtaken as indicated at line 9 of Fig. l; Fig. l0, an elevational view,partly in section, of a presser-shoe and associated stripper-arm; Fig.11, a broken elevational view showing the relation between the pressershoe and ridge-depressing wheel; Fig. 12, a sectional view of a cushionembodying the invention; Fig. 13, a broken perspective view of a cushionhaving the improved M-shape seam; Fig. 14, a broken plan view showing anextension tacked onto the cover fabric; Fig. 15, a broken frontsectional view oi' a forming-roll and ridge-bar for forming a pleat withthe extension for the cover-fabric; Fig. 16', a sectional view showingthe extension attached to the cushion; Fig. 17, a modification showing afabric with animproved ridge-seam having. a connecting tape nestedtherein and sewed to form a backing for the seam; Fig. 18,

another modification wherein the tape is sufilciently wide to completelyenclose the underside of the seam; Fig. 19 shows a series of fabrics foruse in covering a panel and provided with connecting tapes of thecharacter shown in Fig. 18; and Fig.20, a vertical sectional viewshowing a tape-tensioning device used when tapes are sewed to thefabric`ln a machine of the general character shown in Fig. 1. e

The construction of the machine is similar to that shown in my abovepatent and the -parts operate in substantially the same way. In theembodiment illustrated, A designates a main frame which is equipped atits iront end with a vertically adjustable cross-head A; B, a frontsuction-conveyor mounted in the bed of the machine; C, a series ofsewing mechanisms mounted on the cross-head and'actuated byia commonV eshaft C; D and D', a pair of front feed rolls upholstery through thefront end of the machine; E, a forming-roll disposed back of and carriedby the lower portion of the cross-head A; F, longitudinal ridge-barswhich cooperate with the forming-roll to form the seam-ridges; G, aseries of lining-creasers mounted on a transverse bar G carried by thehead; H, batt-feeding rolls journaled in supports carried by the mainframe; and I, a series of guides or short chutes serving to guide thebatts to the forming-roll E.

The main frame A, cross-head A', conveyor B, sewing mechanism C, andfeed-rolls D and D are substantially the-same as those described in thepatent above.

The forming-rolls E are laterally adjustable on the cross-shaft 2l andpreferably formed in two parts 22 and 23. Each provides a groove 24 fromwhich projects a grooved ridge-depressing wheel 25. As shown in Fig. 9,the parts may be connected together by suitable rivets 26 and theforming-roll is adjustably secured to the shaft 2| by means of a set'screw 21. As will be understood, the sewing mechanisms and cooperatingparts of the machine are also adjustable later-v ally in order to formpleats of various widths.

The ridge-bar F, best shown in Figs. 1 and 2, is xed t'o the frame ofthe machine just above the suction-conveyor B. As will be understoodfrom the sectional views in Figs. 3 and 6, the rear portion of the baris substantially square, as indicated at 28, and tapers downwardly andforwardly towards the front of the machine in steps to a point 29. Theridge-bar is provided with an upwardly open longitudinal slot 30 inwhich the crown portion of the ridge-seam is depressed so as to becomeM-shaped. Above the ridge-bars are i'lxed forming-shoes 3| which extenddown and partially enclose the ridge-bar F. Thus it will be understoodthat as a fabric-cover or blank 32 is fed forwardly over the ridge-bar Fby means of the suction-conveyor B, the seam-portion will first be oiinverted U-form, as shown in Fig. 3, and gradually have its crownportion depressed to become M-shaped, as shown progressively in Figs. 4and 5. At the same time, a lining-fabric 33 is formed into correspondingseam-portions by the forming-shoes G and comes into contact with thecover-fabric 32 at the forming-roll E. .The ridge-depressing wheel neststhe seam-portions of the two fabric and they are advanced to the sewingmechanism C in this relation. It will be understood, also, that thecotton batts 34 are fed into the pleat-fulnesses in timed relation tothe movements of the cover and lining-fabrics by means of the rolls H.

As shown in Figs. 1, 10 and 11, a presser-shoe 35 is mounted on thelower end of the cross-head A' and is equipped with a rearwardlyextending stripper-arm 36 which extends back into the groove of thewheel 25 and is pivotally mounted on the presser-shoe at 31. A spring 38is arranged to urge the rear portion of the stripperarm upwardly and aset screw 39 is provided to adjust the stripper-arm to accommodatevarious depths of seams. The stripper-arm serves to prevent the crownportion of the seam-ridge from following the rotation of the wheel 25Yupwardly.

As shown in Figs. l and 8, the seam-portions in the lining-fabric areformed by the liningcreasers G which comprise a pair of forwardlyinclined bars 40 between which the lining-fabric is pressed by means ofa parallel bar 4| which is fastened to a bracket 42 by means of a screw43.

G' which, in turn, is supported on the crosshead A'.

It hasbeen dlmcult to obtain cover-fabrics of sufilcient width to form acomplete cushion in one piece and, accordingly, the practice has been tosew on to the sides of the cushion lateral extensions which are known inthe trade as hams. As shown in Figs. 13-16, in the present invention thehams 44 may be tacked to the coverfabric 32 by means oi.' stitching 45.Preferably, a butt-seam is employed. As shown in Fig. 15, a specialridge-bar 46 is employed to cooperate with the forming-roll E and thepresser shoe 35 to form the end M-shape seam-ridge which contains thebutt-seam between the cover-fabric and ham 44. y

When the upholstery blanks are to be used for covering lining panelsrather than stuffed cushions, the lining-fabric 33 is not needed andtapes 49 may be substituted. When such tapes are used, the formers G maybe omitted and tapetensioning devices 50 shown irr Fig. 20 may bemounted on the cross-head A in their places. The tensioning device maycomprise a rearwardly extending plate 5l equipped with grooved rollers52 around which the tape passes on its way to the forming-roll E. If thetape is of sufiicient width, the transverse stitches 53 which arefcrmedby the sewing-needle 54 and louper-needle 55 of the sewing mechanism Cmay pass through four thicknesses of both the cover-fabric and tape.However, if desired, a narrower tape may be used, as shown in Fig. 17,wherein the stitching 53 passes through four thicknesses of thecover-fabric and but two thicknesses of a tape 56. As shown in Fig. 19,the covers 32 are connected in series by means of the tapes 49 and thisconnection enables the feed-rolls D and D' `to withdraw the upholsteryfrom the machine and facilitates subsequent folding operations. Thetapes, of course, may be severed when the upholstery is ready to beapplied to a lining panel.

'Ihe foregoing detailed description has been given for clearness ofunderstanding only, and no unnecessary limitations should be understoodtherefrom, but the appended claims should be construed as broadly aspermissible, in view of the prior art.

What I claim as new, and desire to secure by Letters Patents, is:

l. In upholstery manufacture: feeding a cover-fabric and progressivelyforming an M- shape seam-ridge therein; feeding a second fabric andprogressively forming an M-shape' seam-ridge therein and nesting theseam-ridges; and connecting the plies of the forwardly advancingsteam-ridges by transverse stitches.

2. In upholstery manufacture: feeding a cover-fabric and forming thereina seam-ridge of inverted U-form and subsequently progressivelydepressing the central portion of the crown to produce an M-formseam-ridge; feeding a second fabric and progressively forming aseamridge therein and nesting the seam-ridges; and connecting the pliesof the seam-ridges by transverse stitches.

3. In upholstery manufacture, the steps which comprise: pneumaticallygripping and carrying a cover-fabric and forming therein inverted U-shape seam-portions and intervening depressed pleat-fulnesses;progressively depressing the central portion of the crowns of saidseam-portions to produce M-shape seam-ridges; progressively formingseam-portions in a second fabric and bringing said fabric to superposedrelation `transverse stitches.

s. In upholstery manufacture, the steps which comprise: pneumaticaliygripping and carrying a cover-fabric and forming therein inverted U-shape seam-portions and intervening depressed pleat-fulnesses;progressively depressing the oentral portion of the crowns of saidsteam-portions to produce M-shape seam-ridges; forming seamportions in asecond fabric and bringing said fabric to superposed relation withrespect to the cover-fabric and nesting the seam-ridges of the twofabrics; feeding continuous strips of batting intofthe pleat-fulnesses;and sewing together the seam-portions of said fabrics with transversestitches.

In upholstery manufacture: feeding a cover-fabric and progressivelyforming an M- `shape seam-ridge therein; feeding a second fabric andprogressively forming an M-shape seam-ridge therein, and nesting theseam-ridges: and connecting all eight plies of the seam-ridges bytransverse stitches.

6. A process which comprises: advancing precut covers seriatim;progressively forming M- shape seam-ridges in said forwardly advancingcovers; and applying and sewing continuous tapes as bracings to theseams. l

7. A process of the character set forth which comprises: advancingpre-cut fabric-blanks seriatim; forming M-shape seam ridges successivelyin said blanks; feeding a continuous fabric ao that it contacts with theseam-portions of the formed blanks in succession; and sewing withtransverse stitches the seam portions vof the blanks to the continuousfabric while the fabrics advance in unison.

a spaced from 8. In an upholstery machine: means for feed- 4 bar fordepressing the fabric into said slot; and

means for rsewing together the four plies of the seam-ridge.

9. In an upholstery machine: means for feeding a cover-fabric; means forforming an M- shape seam-ridge in said fabric which comprises alongitudinally lextending ridge-bar having an upwardly open longitudinalslot, a forming-roll having a circumferential groove adapted to rereivesaid ridge-bar, and a ridge-depressing member in said groove projectinginto said slot; and means for sewing together the four vplies of theseam-ridge.

10. In an upholstery machine: means for feeding a cover-fabric; meansfor forming an M- shape seam-ridge in said fabric which comprises alongitudinally vextending ridge-bar having an upwardly open longitudinalslot, a forming-roll having a circumferential groove adapted to receivesaid ridge-bar, a grooved ridge-depressing wheel in said grooveprojecting into said slot, and a stripper-arm mounted above said ridge.-bar and extending into the groove in said ridgedepressing wheel; andmeans for sewing together the four plies of the seam-ridge.

11. In a machine of the character set forth: feeding mechanism; andmechanism for forming an M-shape seam in a fabric advanced by saidfeeding mechanism comprising a. ridge-bar having a longitudinal slot, aforming-roll having a groove partially enclosing said ridge-bar inspaced relation, and a ridge-depressing wheel mounted on saidforming-roll and projecting from said groove into the slot in saidridge-bar.

12. In a machine of the character set forth: feeding mechanism; andmechanism for forming an M-shape seam in a fabric advanced by saidfeeding mechanism comprising a ridge-bar having a longitudinal slot, aforming-roll having a groove partially enclosing .said ridge-bar inspaced relation, a grooved ridge-depressing wheel mounted on saidforming-roll and projecting from said groove into the slot'in saidridge-bar, and a presser-shoe in the rear of said formingwheel providedwith a forwardly extending stripper-arm projecting into said groovedwheel.

ALLISTER S.

